Control system for welding heads



Jan. 29, 1946. J. SKUHROVEC CONTROL SYSTEM FOR WELDING HEADS Filed Dec. 13, 1943 2 Sheets-Sheet l INVENTOR. Joseph Skuhrovec BY *Qk ATTORNEYS J. SKUHROVEC CONTROL SYSTEM FOR WELDING HEADS Filed Dec. 13, 1943 2 Sheets-Sheet 2 Jan. 29, 1946.

INVENTOI Q. J'aseph ,Skuhrovec BY Patented Jan. 29, 1946 CONTROL SYSTEM FOR WELDING HEADS Joseph Skuhmee, Cleveland, Ohio, assignor to Una Welding, Inc., Cleveland, Ohio, I corporation of Ohio Application December 13, 1948, Serial No. 514,092 8 Claims. (Cl. 314-62) This invention relates to an electrode operating mechanism for welding heads and more particularly to an electrical control for the electrode operating motors.

The present invention provides an improved motor control for welding heads of the typ in which the electrode is actuated by two simultaneously operating motors that are geared to the electrode feed mechanism through a suitable diflerential so as to impart to the feed mechanism a movement that is the resultant of the speeds or the two motors.

The present invention has for its object to provide a control for the electrode operating motors in which the speed of one of themotors is so controlled by the voltage across the are as to eliminate jerky movements 01 the electrode during its movements toward and away from the work in striking the arc and during the welding operation.

More specifically it is the object of the present invention to provide a control ot the character described that acts through a field winding of a shunt wound motor to vary the speed of the motor and toso stabilize or dampen the electromagnetic forces as to prevent sudden fluctuations in speed that would impart jerky movements to the electrode.

With the above and other objects in view the invention may be said to comprise the electrode operating mechanism as shown in the accompanying drawings hereinafter described and particularly set forth in the appended claims together with such variations and modifications thereof as will be apparent to one skilled in the art to which the invention pertains.

Reference should be had to the accompanying drawings in which;

Fig. 1 is a wiring diagram showing the invention applied to-a welding head that is provided with a constant potential welding generator.

Fig. 2 is a wiring diagram showing the invention applied to a welding head that has a variable voltage generator.

In welding machines oi' the type to which the present invention is applied an electrode I is moved toward and away from a work piece 2' by a suitable feed mechanism driven through a diflerential gearing 3 by two electric motors l and 5. The two motors drive the axially alined 1 shafts oi the difi'erential 3 and the electrode i is actuated by the ring gear at a speed that is the resultant of the speeds oi the two motors. :The motor I is a motor of constant speed char teeteristics and may be either an A. C. or D. C. 65

motor. The motor 5 is a D. C. shunt wound motor having a normal speed of rotation somewhat higher than the motor 4. The motor 4 rotates in a direction to elevate the electrode and may be termed the "up motor. The motor 5 rotates in a direction to lower the electrode toward the work and may be called the "down" motor; The motors are controlled during operation to move the electrode to strike an arc and to automatically maintain an are 01' a predetermined length.

In the embodiment of the invention shown in Fig. 1 current for welding and for operation oi the down motor I is supplied by a constant potential welding generator 8. The welding electrode I is adapted to receive current from one terminal of the generator 6 through a wire 1 an adjustable resistance 8 a series relay 9 a wire III a switch Ii and wires l2 and It. The series relay 9 is designed to actuate its armature only upon passage 01' a predetermined current therethrough and the resistance 8 may be adjusted to regulate-amount of current that is delivered to the welding circuit. The work 2 is connected to the opposite terminal 01' the generator 8 through a wire I 4. An arc regulating resistance II in parallel with the arc is connected by a wire I. to the wire and through one or more of the adjustable contacts l'l, I8 and I! to the wire I, contact I! being connected directly to the wire I. The contact ll may beconnected to the wire I through a switch 2| and the contact I! may be connected to the wire I through a switch 2i.

The down motor 5 has one terminal or its armature connected by a wire 22 to an adjustable contact 23 engaging the resistance l5 and its opposite terminal connected through a wire 24 to the wire I. A circuit is thus provided from one terminal oi. the generator 8 through wires II and I2, the switch H, the wire ill, the coil 9,

- the resistance 8, the wire I, the resistance ii, the

contact 23, the wire 22, the armature of motor I and the wires 24 and I4 to the opposite terminal of the generator. During operation of the machine the switch 204s operated to cut out a major portion of the resistance l5 to speed up the down motor I and the switch 2| is operated while the machine is being stopped to cut back a portion of the resistance and slow down the motor I.

The down motor 5 has a main shunt field winding 25 that has one terminal connected to a terminal of the generator 8 through the wire I! and its opposite terminal is adapted to be connected through a wire 20, a switch 21 and the wire II to the opposite terminal of the generator.

The down motor I has an auxiliary shunt ileld winding 28 that is connected across the arc, one terminal being connected by a wire II and wire I to the electrode I and the other terminal being connected by wires III, II and II to the work 2.

The amount of current supplied to the winding 28 may be regulated, if desired, by a suitable adjustable resistance in series with the winding, such as the adjustable resistance II shown in Fig. 2.

The generator circuits are so controlled that upon initial energization the down motor I is first operated to move the electrode I toward the work 2 to strike an are after which the up motor I is started into operation to reverse the movement of the electrode, after which the speed or the motor I is increased to again reverse the movement of the'electrode and to maintain a uniform arc. I

A starting switch II which may be of the push button type, has one contact connected to the wire 28 and its other contact connected by a wire I! to the wire II. When the starting switch II is closed a. circuit is completed from one terminal of the generator I through the wires II and I2, 9. wire II, a normally closed switch II. a wire II, a solenoid II, the wire II, the switch II and the wires II and II to the opposite terminal or the generator I. Since the motor winding II is in parallel with the coil II between the wires II and II a portion of the current will flow through the winding II. Current flowing through the solenoid II energizes the same and closes the switches II and 21.

The switch 21 when closed completes a circuit from one terminal oi. the'generator I through the wire II, the winding II, and wires II and II and also a holding circuit through the wires II, II and II, the switch, II, the wire II, the solenoid II, the wire II and the wire II to the opposite terminal or the generator.

Closing of the switch II completes a circuit from one terminal of the generator I through the wires II and II, the switch H, the wire II, the series relay coil I, the resistance I, the wire I, the regulating resistance II, the wire 22, the armature of the motor I and wires II and II to the opposite terminal of the generator I.

Since the motor winding II is connected in parallel with the resistance II across the arc current will also flow through wires 1 and II, winding II and wires II, II and II to generator I.

Current flowing through the armature of the motor I and through the shunt windings thereof upon the closing of switches II and 21 starts the down motor I into operation to feed the electrode in a downward direction. Initially there is a relatively light current passing through the series relay I due to the fact that this coil is in parallel with the coil II and winding II and in series with a relatively high resistance when the electrode I is spaced from the work 2. The relay I actuates a normally open switch I! but is so designed that it imparts movement to the switch only when a predetermined current passes through it. when the electrode I approaches and contacts the work 2 the coil I I winding II and the armature oi the motor I are short circuited stopping or greatly reducing the speed of the down motor I. The short circuiting ot the resistance II causes a surge of current through the coil I which energizes the coil and closes the switch I1.

Closing the switch I1 completes a circuit Irom one terminal the generator I through the wires II and II, a solenoid II, a wire II, the switch 31, a wire II, the wire II, the switch 21, and the wire II to the opposite terminal 0! the generator. The solenoid II when energized closes a switch I: that starts the up motor I and reverses the direction oi movement of the electrode.

In order to check and limit the upward movement of the electrode it is necessary to quickly accelerate the down motor I to a speed somewhat greater than that of the up motor I to arrest the upward movement oi the electrode I and to start a uniiorm downward ieed movement at a rate to compensate for electrode metal consumed by the arc. To eflect a suitable adjustment of the down motor control circuits to eiiect this speed up the switch Il completes a second circuit from one terminal oi the generator I, the wires II and II, a wire II, a normally closed switch II, a wire II, a solenoid II, a wire II, the wire II, the switch I1, the wires II and II. the switch 21 and the wire II to the opposite terminal of the generator I. Energization ot the solenoid II closes the switch II and short circuits the major portion of the regulating resistance II so that the current through the armature and shunt winding II oi the down motor I is considerably increased.

Energization or the series relay I starts the welding operation, and may also start the movement of parts of the machine other than the electrode. The solenoid II controlled by the relay I may operate a second switch II in an independent circuit which may control the usual work feed mechanism.

During operation, the circuits controlling the II motor I are automatically responsive to variations in the voltage across the arc to automatically vary the speed of the motor to maintain a uniform are. Because of the fact that both the main and auxiliary windings are shunt windings and because of the (act that the auxiliary winding is connected across the arc, the control circuits are stabilized or dampened sumciently to prevent objectionably rapid acceleration or deceleration of the down motor I due to fluctuations or voltage across the arc during operation. The control 0! the down motor provided by the present invention prevents overspeeding due to the initial high voltage momentarily impressed upon the down motor during the are starting period.

The system is deenergized by means of a stop switch II which may be or the push button type and which, when closed, completes a circuit from one terminal of the generator I, through the wires II and II, a time delay relay II, a wire I2, the switch II, a wire II, the wires II and II, the switch 21 and the wire II to the opposite terminal of the generator I. Energlzation of the delay relay II opens the switch II after a predetermined short time interval, breaking the holding circuit through the solenoid II and permitting switches II and 21 to open. The opening 0! the switches II and 21 opens the down motor and welding circuits, deenergizing the series relay I and allowing the switch II to open. Opening of the switch II deenergizes the solenoid II, breaking the circuit of the up motor I.

Closing the switch II also closes a circuit from one terminal of the generator I through the wire II, a wire II, a solenoid II. a wire II, the wire II, the switch II, the wires II, II, and II, the switch 21 and the wire Il to the opposite terminal oi the generator 5.

Energization oi the solenoid 55 closes the switch 2| to connect the intermediate contact is to the wire 1. Energization of the solenoid 55 also opens the normally closed switch ll to deenergize the solenoid l6 before the circuit though the coil 9 is broken opening the switch 20 so that a greater portion of the resistance I5 is cut into the armature circuit through the contact I9 andswitch M to decelerate the down motor during the short time interval elapsing between the closing of the stop switch l5 and the breaking of the welding and motor control circuits by the opening of the switches II and 21.

To insure the continued energization of the solenoid as during the time interval between the closing or the sto switch l9 and the opening of the operating circuits, the solenoid 55 actuates a holding switch 51 connected in arallel with the stop switch l9 by means of a wire 58 connecting one terminal of the switch 51 to the wire H and a wire 59 connecting the other terminal thereof to the wire 55. The deceleration of the down motor 5 during the time interval provided by the delay relay 5I causes the electrode I to be retracted from the work when the machine is stopped. The extent oi movement of the electrode away from the work may be limited by suitable means and, ii desired, the motors l and 5 may be equipped with suitable automatically controlled brakes to limit the coasting thereof after deenergization as is well understood in the art.

The invention may be applied to a welding machine having a variable voltage generator by employing a D. C. motor generator set for supplying current to the main shunt winding of the down motor 5 as shown in Fig. 2. The same control relays solenoids and switches are employed as in Fig; 1 and these parts are designated by the same reference numerals as in Fig. 1. The welding generator 5a is connected through the wire Il to the work 2 and through the wire II, the switch II, wire I and series relay 8 to the electrode. The resistance 5 shown in Fig. 1 is not necessary because all of the current from the generator 6a passes through the series relay 2. The armature and the auxiliary shunt winding 28 oi thedown motor 5 are connected across the arc in the same way as in Fig. l, the resistance 25a which may be placed in series with the winding 25 being shown in this view. The D. C. motor generator set has a generator 60 driven by a motor 5|. The generator 50 has a shunt field 52, a regulating resistance 85 and a series field N. The opposite terminals of the generator 50 are connected to wires Ila and Ila to which all of the energizing relays and solenoids except the series relay 9 are connected, the wires oi. the con trol circuits other than the welding circuits and the down motor circuits associated therewith being connected to the wires Ila and Ila in the same manner as they were connected to the wires I3 and Il in Fig.1. a

For convenience of illustration some of the wires in Fig. 2 are arranged somewhat diil'erently. Such wires are indicated by thesame reference numerals as in Fig. 1 with the addition 01' the letter fafe. g., 53a, 35a, lla and Ma.

The starting circuit is from generator lll through wires I la, la, switch ll, wire 55, solenoids 85. wire'25, push button switch ll, and wires 82 and Ila to generator. For the holding circuit switch 21 connects the wire 25 to wire Ila in parallel with switch ll and wire 82.

The shunt winding 25 is connected to the wire Ila and through wires 28 and switch 21 to the wire Ila, being in parallel with solenoid 38.

The circuit through the up motor control solenoid I! completed by closing the switch 31 is from generator through wires I3a and 38a, the solenoid 39, the wire ID, the switch 31, wires H and 25, switch 21 and wire Ila to the generator 50.

Th circuit through the speed control and work feedaontrol solenoid l5 completed by closin the switch 31 is from generator 50 through wires Ila, 33a, lla, thenormally closed switch ll, the wire l5, the solenoid l5, wires l1 and lo, switch I1, wires ll, 25, the switch 21. and the wire Ila to the generator 60. I

The stop push button l9 closes circuits through the time relay 5| and the solenoid 55. The relay II is connected to wire Ila by wires 50 and 33a and and to the wire Ila through wire 52, switch 49, wires 53, H, and 28, and the switch 21. The solenoid 55 is connected to the wire I3a by wires m and Ila and to the wire Ila through wires 58 and 52, the switch l9, wires 53, H and 25 and the switch 21.

The solenoid 55 closes a holding switch 51 that provides a connection from the relay 5| to the wire Ila through wires 52, 58 and 59, switch 51, wires 58, H and 25 and the switch 21, and a connection from the solenoid 55 to the wire Ila through wires 58 and 59, the. switch 51, wires 58, H and 26 and the switch 21.

It is to be understood that the embodiments of the invention herein shown are illustrative only and that many variations in detail thereof may be resorted to without departing from the invention herein claimed.

What I claim is:

1. In a welding machine having a work support and an electrode movable toward and away from the work by a feed mechanism driven through a differential, two drivers operating said diii'erential, one of said drivers being a shunt wound motor having a main field winding and an auxiliary field winding connected to aid and strengthen the magnetic field oi the main winding, said auxiliary winding being connected directly across the are.

2. In a welding machine having a work support and an electrode movable toward and away from the work by a feed mechanism driven through a difi'erential, two drivers operating said differential, one or said drivers being a shunt wound motor having its armature and a field winding connected across the are, a resistance in "series with the armature, and means controlled by the current in the welding circuit for varying said resistance.

3. In a welding machine having a work support and an electrode movable toward and away from the work by a feed mechanism driven through a difl'erential, two drivers operating said diflerential, one or said drivers being a shunt wound motor having a field winding connected across the arc, and means controlled by the cur rent passing through the electrode for varying the ratio of the current through said field winding to the current through the armature or said motor.

arate field windings and having its armature and one of its neld windings connected across the are, a resistance in series with the armature, and a resistance of predetermined value in series with said winding, the second-field winding being connected to a separate and independent source of constant potential.

5. In a welding machine having a work suport and an electrode movable toward and away from the work by a feed mechanism driven through a differential, an up motor having a driving connection to said diilerential, a shunt wound down motor having a driving connection to said difierential and having its armature and a field winding connected across the arc, and a resistance parallel with the armature and of a value such as to exert a dynamic braking effect.

6. In a welding machine, a work support, an electrode movable toward and away from the work, an electrode actuating mechanism comprising a differential and up and down motors driving said differential, one of said motors being a shunt wound motor having a plurality of field windings, the armature o! the shunt wound motor and one of its windings being connected across the arc and means controlled by the current passing through the welding circuit for varying the resistance of the armature circuit.

7. In a welding machine, a work support, an

electrode movable toward and awayfrom the work, an electrode actuating mechanism comprising a diflerential and up and down motors driving said diflerential, one or said motors being a shunt wound motor having a plurality of field windings, the armature and windings of said shunt wound motor being in parallel with the are. an adjustable resistance in series with the electrode and with the armature and one of said windings, a second variable resistance in series with the armature, and means controlled by the current passing through the electrode for increasin or decreasing said variable resistance.

8. In a welding machine, a work support, an electrode movable toward and away from the work, an electrode actuating mechanism comprising a diflerential and up and down motors driving said differential, one of said motors being a shunt wound motor having a plurality of iield windings. the armature and windings of said shunt wound motor being in parallel with the are, an adjustable resistance in series with the electrode and with the armature and one oi said windings, a second variable resistance in series with the armature, a second adjustable resistance in series with the last mentioned winding, and means controlled by the current passing through the electrode for increasing or decreasing said variable resistance.

JOSEPH SKUHROVEC. 

